Formable inserts and related methods

ABSTRACT

Formable inserts and related methods are disclosed herein. An example of forming a cover with a formable insert includes forming a first frame portion of the cover, attaching a formable insert to the first frame portion of the cover, and forming a second frame portion of the cover subsequent to the formation of the first frame portion to capture a perimeter edge of the formable insert in the second frame portion of the cover.

FIELD OF DISCLOSURE

The present disclosure relates to molded parts, including but notlimited to, formable inserts and related methods.

BACKGROUND

Electronic devices, including portable electronic devices, have gainedwidespread use and may provide a variety of functions including, forexample, telephonic, electronic messaging, and other personalinformation manager (PIM) application functions. Portable electronicdevices include, for example, several types of mobile stations such assimple cellular telephones, smart telephones, tablet computers, wirelesspersonal digital assistants (PDAs), and laptop computers with wireless802.11 or Bluetooth capabilities.

Electronic devices such as, for example, portable electronic devicesemploy a housing to enclose or contain various electronic or mobilecomponents such as a microprocessor, a display, a keypad, a speaker, amicrophone, etc. The housing may include a front cover or lid thatcouples to a frame or base to capture the electronic components withinthe housing.

Some known electronic devices employ a formable insert (e.g., a fabricor leather) applied to a cover to provide desirable attributes such asaesthetic appearance, desirable contact surface for gripping or feel,design variations or the like. Typically, the insert is attached to thecover via insert molding. In some instances, however, it can bedifficult to provide a robust attachment of the insert to the cover. Asa result, the insert can detach from the cover. In particular, edges ofthe insert fray or become damaged. In some instances, a parting line(e.g., due to mold tool) forms between the insert and the cover that isvisible from an exterior surface of the electronic device and can beaesthetically unappealing.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a first side of an example cover having a formableinsert formed in accordance with the teachings disclosed herein.

FIG. 1B illustrates a second side of the example cover of FIG. 1A.

FIG. 2 illustrates an example first frame of the example cover of FIGS.1A and 1B.

FIG. 3A illustrates a first side of the example formable insert of FIGS.1A and 1B prior to being attached to the example cover.

FIG. 3B illustrates a second side of the example formable insert of FIG.3.

FIG. 4 illustrates the example formable insert of FIG. 3A and FIG. 3Battached to the example first frame of FIG. 2.

FIG. 5 illustrates another view of the example formable insert and theexample first frame of FIG. 4.

FIG. 6 illustrates the example first frame and the attached formableinsert positioned in a mold tool.

FIG. 7 illustrates a portion of the example formable insert foldedrelative to the example first frame when the first frame and theformable insert are positioned in the mold tool.

FIG. 8 illustrates an example second frame of the cover formed via themold tool.

FIG. 9 is a flowchart of an example process to form an example part inaccordance with the teachings described herein.

DETAILED DESCRIPTION

Certain examples are shown in the above-identified figures and describedin detail below. In describing these examples, like or identicalreference numbers are used to identify common or similar elements. Thefigures are not necessarily to scale and certain features and certainviews of the figures may be shown exaggerated in scale or in schematicfor clarity. Additionally, several examples have been describedthroughout this specification. Any features from any example may beincluded with, a replacement for, or otherwise combined with otherfeatures from other examples.

Formable insert materials (e.g., fabrics, leathers, decorativelaminates, etc.) are often applied to molded parts such as plasticsubstrates via in-molding insert manufacturing methods. For example, acover of an electronic device may be provided with a fabric ordecorative laminate. Some known processes apply the formable insert tothe plastic substrate via injection molding. The known insert may be aplanar overlay or may be pre-formed and cut to fit the mold tool cavity.After the insert is provided in the mold, molding resin is injected intothe mold cavity to form the plastic substrate. In turn, the insert bondsto the molding resin as the molding resin cools to form an integralpart. To prevent inserts from burning or melting due to the temperatureof the molding resin, an insulating material(s) is often employed anddisposed between the insert and the molding resin. In some instances,the insert may be provided with an additional thickness to protect theinsert from damage (e.g., burning) due to the relatively hightemperatures of molten resin during the molding process. For example, aninsert may have an additional thickness of approximately between 0.05and 0.18 millimeters. In some examples, to reduce damage to the insertmaterial, the resin thickness may be relatively greater (e.g.,increased) to reduce pressure and/or surface area heat that wouldotherwise be transferred to the insert during, for example, insertmolding. Typically, for insert molding, a resin thickness up to 0.4millimeters may be provided to reduce pressures, heat and/or friction.

To form an example part or frame (e.g., a cover) disclosed herein, afirst substrate or a first frame portion is provided, molded, or formed.For example, the first frame portion is formed having a slightly smallerdimensional profile relative to the dimensional profile of the part orframe (e.g., the intended final part). For example, the first frameportion may have at least one dimensional value that is less than arespective dimensional value of the part (e.g., the final product orframe). An example first frame portion disclosed herein may have a firstdimensional height (e.g., a height between a first side or back side anda second side or front side of the first frame portion) that is lessthan a respective dimensional height of the part. In some examples, thedimensional height of the first frame portion may be approximatelybetween 0.2 and 10 millimeters less than the dimensional height of thepart.

As a result, providing the first frame portion with a dimensional valueless than the dimensional value of the part enables a portion of aformable insert or an exoskeleton or exterior skin to be folded relativeto the first frame portion. For example, the formable insert may beattached to the first frame portion to provide a foldable portion or lipprotruding from a respective edge of the first frame portion.

In this manner, the lip may be folded relative to the first frameportion and a second frame portion may be formed or created to seal,encase or otherwise capture a perimeter edge of the lip and/or theexoskeleton formable insert in the second frame portion when the lip isfolded toward the first frame portion. As a result, the perimeter edgeof the lip of an example cover disclosed herein may not be visible froman exterior surface of the part. In some examples, the formable insertmay be formed and/or shaped via thermoforming. Further, a second frameportion disclosed herein may provide the remaining portion of the part.For example, an example first frame portion disclosed herein may have adimensional height that is approximately between 0.2 millimeters and 10millimeters less than a dimensional height of an example part. Thesecond frame portion, for example, may have a dimensional height ofapproximately between 0.2 millimeters and 10 millimeters.

To seal or otherwise cover the perimeter edge of the example formableinsert disclosed herein, the first frame portion and the formable insertmay be undermolded with a material (e.g., plastic). The material, whencooled, defines the second frame portion. For example, the formableinsert and the first frame portion may be positioned in a cavity of amold tool and the lip of the formable insert may be folded relative to aparting line of the mold tool. A slide or tool, for example, may beemployed to fold the lip relative to the parting line of the mold tooltoward the first frame portion while the insert and the first frameportion are inside the cavity of the mold tool. As the slide folds thelip relative to the parting line of the mold tool, a portion of theformable insert may be undermolded with molding resin to seal theperimeter edge. Thus, a part or frame of the illustrated examplesdisclosed herein includes the first frame portion, the second frameportion and the formable insert. Before the formation of the secondframe portion, the formable insert is applied or attached to the firstframe portion. As a result of the example methods disclosed herein,secondary trimming operations otherwise required to trim the edges ofthe formable insert may not be needed and/or may be employed reducingthe precision required during trimming (e.g., does not require trimmingto a relatively small dimensional value or tolerance).

Example formable inserts and related methods described herein generallyprovide a decorative or aesthetically appealing surface to a substrateor a frame (e.g., a plastic substrate, a metal substrate, etc.). Morespecifically, a perimeter edge of a formable insert as disclosed hereinis not visible from an exterior surface of the formable insert and/orthe frame. In particular, the perimeter edge of the formable insert isembedded, sealed, encased or otherwise covered to prevent the edge ofthe formable insert from fraying or becoming damaged (e.g., from peelingaway from a surface of a frame), thereby increasing the durability of apart.

FIGS. 1A and 1B illustrate an example part or frame 100 having aformable insert 102 in accordance with the teachings disclosed herein.FIG. 1A illustrates a first or outer surface 104 of the part 100. FIG.1B illustrates a second or inner surface 106 of the part 100. In theillustrated example of FIGS. 1A and 1B, the part 100 is a cover 108 suchas, for example, a battery cover. The cover 108 has a profile (e.g., ashape and/or size) to engage (e.g., matably engage) another housingportion (not shown) of an electronic device such as, for example, aportable electronic device. For example, the cover 108 may be used toimplement a housing of a mobile device that can be held in one hand by auser of the mobile device during data (e.g., text) and/or voicecommunications.

As shown in FIGS. 1A and 1B, the example formable insert 102 does nothave a parting line visible from the outer surface 104 of the cover 108.To eliminate or otherwise hide from view the parting line from the outersurface 104 of the cover 108, a foldable portion 110 of the formableinsert 102 is folded toward an inner surface 112 of the cover 108. Morespecifically, the foldable portion 110 of the formable insert 102 isfolded relative to a first frame 114 of the cover 108 and is sealed,captured or encased by a second frame 116 of the cover 108. As describedbelow, to seal the example foldable portion 110 of the formable insert102 in the second frame 116, the second frame 116 is formed subsequentto the formation of the first frame 114. Thus, the example formableinsert 102 is attached or coupled to the first frame 114 prior toformation of the second frame 116. As shown in the illustrated example,the first frame 114 and the second frame 116 form a substantiallyunitary structure.

The example second frame 116 secures, seals, attaches, captures and/orotherwise couples the folded portion of the formable insert relative tothe inner surface 112 of the first frame 114. More specifically,perimeter edges (not shown) of the formable insert 102 are encased,embedded or otherwise captured by the second frame 116 and, thus, arehidden. As a result, the perimeter edges of the formable insert 102 areless susceptible to fraying or becoming damaged (e.g., peeling away fromthe first frame 114).

Referring to FIG. 1B, the example cover 108 has perimeter edges 118 thatdefine a shape or profile of the cover 108. The cover 108 of theillustrated example has sides 120 that protrude from a base 122 of thefirst frame 114 to define a cavity 124. The cavity 124 may receive, forexample, electronic components of a mobile device (e.g., amicroprocessor, a battery, etc.). The sides 120 of the cover 108 have adimensional height or value 126. In particular, the dimensional height126 of the cover 108 is defined by a dimensional height 128 of the firstframe 114 and a dimensional height 130 of the example second frame 116.Thus, the first frame 114 includes a dimensional value (e.g. thedimensional height 128) that is less than a respective dimensional value(e.g., the dimensional height 126) of the cover 108. In other words, thefirst frame 114 is formed to have a surface area that is smaller than asurface area of the cover 108. Also, the dimensional height 130 of thesecond frame 116 is approximately equal to the difference between thedimensional height 126 of the cover 108 and the dimensional height 128of the first frame 114. For example, the dimensional height 130 of thesecond frame 116 may be approximately between 0.2 to 10 millimeters.Thus, the sides 120 of the illustrated example are defined by the firstframe 114 and the second frame 116 and each of the first and secondframes 114 and 116 define respective openings that at least partiallydefine the cavity 124 of the cover 108.

FIG. 2 is a bottom view 200 of the example first frame 114 of FIGS. 1Aand 1B. The profile, a shape and/or a size of the first frame 114 ofFIG. 2 is defined by perimeter edges 202. The first frame 114 has adimensional width 204, a dimensional length 206 and the dimensionalheight 128. As noted above, the first frame 114 of FIG. 2 is formedsmaller (e.g., 10% smaller) than the dimensional profile of the part 100or cover 108. For example, the first frame 114 may have a surface areaof approximately between 90% and 99% of a surface area of the cover 108.In particular, the first frame 114 is dimensioned or configured toaccommodate the second frame 116, which is shown in FIG. 2 in dashedlines for illustrative purposes. Thus, compared to the cover 108 ofFIGS. 1A and 1B, the dimensional value (e.g., the dimensional height) ofthe example first frame 114 is approximately less than the dimensionalheight 126 of the part 100 by a dimensional value substantially equal tothe dimensional height 130 of the second frame 116.

The first frame 114 of the illustrated example may be formed viainjection molding, forming, machining and/or any other suitablemanufacturing process(es). For example, a mold tool (e.g., a cavity anda core) may be formed with a cavity having a profile (e.g., a shapeand/or size) substantially similar or identical to the profile, shapeand/or contours of the first frame 114. To form the first frame 114, thecavity of the mold tool is injected with a first molding resin ormaterial. For example, the molding resin or material may be a plastic orother resin material. The first frame 114 of the illustrated example iscomposed of a glass-reinforced nylon resin (PA+50% GF). However, inother examples, the first frame 114 may be composed of any othersuitable material such as a thermoset (e.g., polyurethane), athermoplastic (e.g., polycarbonate, ABS, polyethylene, etc.), acomposite and/or any other suitable material(s). Alternatively, thefirst frame 114 of FIG. 2 may be composed of metal, aluminum, carbonfiber or any other suitable material(s). For example, a frame composedof metal, aluminum or carbon fiber may be formed via machining, forming,stamping and/or any other suitable manufacturing process(es).

Additionally or alternatively, the first frame 114 of the illustratedexample may include openings 208 (e.g., semi-circular or partialopenings) to receive, for example, buttons or other features of a mobiledevice. Additionally or alternatively, the first frame 114 of theillustrated example may be optionally provided with one or more recesses210 to provide for one or more respective gates of a mold tool. As shownin the illustrated example, the recesses 210 have a trapezoidal shape orprofile and are formed adjacent the perimeter edges 202 of the firstframe 114. When the first frame 114 is not formed via injection molding,the recesses 210 may, optionally, not be included.

FIG. 3A illustrates a first or front side of an example formable insert102 of FIGS. 1A and 1B prior to being formed and/or attached to thefirst frame 114. FIG. 3B illustrates a second or back side of theformable insert 102. Referring to FIGS. 3A and 3B, the example formableinsert 102 is defined by perimeter edges 302 having a similar shape orprofile as the first frame 114. In particular, the formable insert 102includes a dimensional length 304, a dimensional width 306 and adimensional thickness 308. For example, the dimensional thickness 308may be approximately 0.5 to 0.75 millimeters. The formable insert 102 ofFIGS. 3A and 3B may be a pre-cut insert or laminate 310 and may beshaped via, for example, stamping, die cutting, laser cutting, and/orany other suitable process(es).

As shown in FIGS. 3A and 3B, the example formable insert 102 issubstantially planar or flat and may be formed in any suitable shape.The formable insert 102 of the illustrated example is real leather. Inother examples, the formable insert 102 may include, but is not limitedto, synthetic leather, suede, textile material such as a woven ornon-woven fabric from natural or synthetic materials, laminate orcomposite materials, and/or a combination thereof to form a multi-layerlaminate formable insert material such as, for example, a leathermaterial layered with a plastic film material. The formable insert 102is generally flexible such that it does not return to a predeterminedshape (such as shown in FIG. 3A) after the formable insert 102 is formedto a desired shape or profile. For example, the formable insert 102 mayconform to the shape or contours of the first frame 114 as shown inFIGS. 1A and 1B. In some examples, the formable insert 102 may becomposed of different fabrics or materials such that different exposedsections of the formable insert 102 may be composed of differentmaterials. Further, in some examples, the formable insert 102 mayinclude indicia 312 such as, for example, a logo, text and/or any otherindicia. For example, the indicia 312 may be provided to the formableinsert 102 via printing, branding, lamination and/or any other suitableprocess(es).

As shown in FIG. 3B, an adhesive 314 (e.g., glue) is applied to a backsurface 316 of the formable insert 102 to attach or bond the formableinsert 102 to the first frame 114. Further, although not shown, abacking or support member may be bonded or coupled to the formableinsert 102. In some examples, the backing member may facilitate shapingor forming the formable insert 102 to the shape of the first frame 114,may stiffen the formable insert 102, and/or may provide support to theformable insert 102 during molding. The backing member may be arelatively thin film member. Some example backing members may include,but are not limited to, films, foams, plastics, fabrics, etc.

FIG. 4 is a front view of the example formable insert 102 attached tothe first frame 114. The formable insert 102 may be applied to the firstframe 114 via adhesive, heat activated adhesive, thermoforming, highpressure forming, vacuum pressure forming, thermal bonding and/or anyother suitable manufacturing process(es). For example, the formableinsert 102 may be pressed on the first frame 114 to conform to theshape, contour or profile of the first frame 114. To facilitate shaping,a pressure may be applied to an outer surface 402 of the formable insert102 and/or a vacuum may be applied to the inner surface 112 of the firstframe 114. In some examples, heat may be applied to the formable insert102 to assist or facilitate shaping or forming the formable insert tothe shape or contours of the first frame.

FIG. 5 is a back view of the example first frame 114 when the formableinsert 102 is attached to the first frame 114. When the formable insert102 is applied or attached to the first frame 114, the example formableinsert 102 defines a lip or edge 502 (e.g., the foldable portion 110 ofFIG. 1B) adjacent the perimeter edges 202 of the first frame 114. Thelip 502 extends or protrudes from the perimeter edges 202 of the firstframe 114 such that the formable insert 102 has a dimensional profilethat is larger than the dimensional profile of the first frame 114. Forexample, the lip 502 may extend a distance 504 of, for example, between0.2 millimeters and 10 millimeters relative to the perimeter edges 202of the first frame 114. Further, in some instances, the lip 502 may betrimmed to define perimeter edges 506 of the formable insert 102. Forexample, the lip 502 may be trimmed to enable the formable insert 102 toproperly fit within a mold cavity as described in greater detail below.The lip 502 of the formable insert 102 is of sufficient length to foldover and/or across the perimeter edges 202 of the example first frame114 of FIG. 1B and FIG. 2 and/or a parting line of a mold tool asdescribed in greater detail below in connection with FIGS. 6-8.

FIGS. 6-8 illustrate an example mold tool 600 to form the second frame116 of FIGS. 1A and 1B. Referring to FIG. 6, the first frame 114 havingthe attached formable insert 102 is positioned in a cavity 602 of themold tool 600. The mold tool 600 includes a first mold part or die 604(e.g., providing the cavity 602) and a second mold part or die 606(e.g., a core). The first frame 114 and the formable insert 102 aredisposed within the cavity 602 of the first die tool 604 and the core606 is positioned relative to the first die tool 604 to form or definean injection cavity 608. In particular, at least a portion of thefoldable portion 110, the lip 502 and/or the perimeter edge 302 of theformable insert 102 is positioned and/or extends into the injectioncavity 608. In some examples, the lip 502 of the formable insert 102 maybe trimmed to fit within the cavity 602 of the mold tool 600.

Referring to FIG. 7, a slide 700 is inserted in an opening 702 of themold tool 600 to engage the lip 502 of the formable insert 102 in themold tool 600. In particular, the example slide 700 folds the lip 502 ofthe formable insert 102 relative to a parting line 704 of the mold tool600 (and/or the perimeter edge 202 of the first frame 114) and towardthe inner surface 112 of the first frame 114. As shown in the example ofFIG. 7, the slide 700 also seals the injection cavity 608.

Referring to FIG. 8, after the lip 502 of the formable insert 102 isfolded relative to the parting line 704, a material is injected into theinjection cavity 608 of the mold tool 600 to form the second frame 116and, thus, the part 100 of FIGS. 1A and 1B. In particular, the materialis injected in the injection cavity 608 between the perimeter edge 302of the foldable portion 110 of the formable insert 102 and the perimeteredge 202 of the first frame 114. As a result, the second frame 116seals, encases, captures or covers the perimeter edges 302 of theformable insert 102. As shown in FIG. 8, the perimeter edge 302 of thefoldable portion 110 of the formable insert 102 has been positioned ororiented toward the inner surface 112 of the first frame 114. Further,the perimeter edge 302 is disposed or embedded in the second frame 116to prevent the perimeter edge 302 from fraying or peeling away from thefirst frame 114 and/or second frame 116, thereby increasing thedurability and/or the aesthetic appeal of the formable insert 102. Thus,in the illustrated example, the lip 502 is trimmed to a length thatenables the foldable portion 110 to fold relative to the first frame114, but prevents the perimeter edge 302 of the lip 502 from protrudingfrom an inner surface 802 of the second frame 116.

Alternatively, in some examples, the perimeter edge 302 may not befolded toward the inner surface 112 of the cover 108. In some suchexamples, the perimeter edge 302 may not be embedded or encased in thesecond frame 116. Further, in some such examples, the perimeter edge 302may be trimmed after the injection of the material to form the secondframe 116.

In the illustrated example, the material used to form the second frame116 is substantially similar or identical to a first material used toform the first frame 114. For example, the first frame 114 and thesecond frame 116 of the illustrated example are formed from aglass-reinforced nylon resin (PA+50% GF). However, in other examples,the second frame 116 may be composed of a material that is differentthan a material of the first frame 114. For example, the first frame 114may be composed of a carbon fiber and the second frame 116 may becomposed of a plastic resin or material. Using different materials forthe first frame 114 and the second frame 116 may provide differentdurability, reduce costs, provide different melting points of thematerials, etc. For example, the second frame 116 may be formed from amaterial having a lower melting temperature than a material used to formthe first frame 114. For example, forming the first and second frames114 and 116 from different materials may reduce damage to the foldableinsert during formation of the second frame 116.

The second frame 116 of the illustrated example is substantially smallerthan the first frame 114. For example, the dimensional height 130 of thesecond frame 116 may be between approximately 0.2 millimeters and 10millimeters. For example, the second frame 116 has a surface area ofapproximately between 1% and 10% of a surface area of the cover 108and/or the first frame 114. Further, the second frame 116 may have adimensional thickness 804 that is substantially similar (e.g., equal to)to a dimensional thickness 806 of the first frame 114. In addition, thesecond frame 116 of the illustrated example defines side walls 808 thatform an opening that defines at least a portion of the cavity 122 of thecover 108 (see FIG. 1B).

Although not shown, mechanical features such as, for examples, hooks,latches, clips, openings, slots and/or another other mechanicalfeature(s) may be provided during formation of the second frame 116 tofacilitate coupling the part 100 to another housing component or cover.

FIG. 9 is a flowchart of an example method 900 to form an example partdisclosed herein (e.g., the example part 100 of FIGS. 1A and 1B). Whilean example manner of forming an example part has been illustrated inFIG. 9, one or more of the steps and/or processes illustrated in FIG. 9may be combined, divided, re-arranged, omitted, eliminated and/orimplemented in any other way. Further still, the example method 900 ofFIG. 9 may include one or more processes and/or steps in addition to, orinstead of, those illustrated in FIG. 9, and/or may include more thanone of any or all of the illustrated processes and/or steps. Further,although the example method 900 is described with reference to the flowchart illustrated in FIG. 9, other methods of forming the example part100 of FIGS. 1A and 1B may alternatively be used.

Referring to FIG. 9, the example method 900 of forming a part includesproviding or forming a frame or substrate portion (e.g., the first frame114 of FIG. 2) (block 902). The frame may be formed via injectionmolding, forming, machining, and/or any other manufacturing process(es).Further, the frame may be composed of any suitable material(s) such as,for example, a plastic material, a metal, a fiber, a composite, an alloyand/or any combination thereof. The example frame is formed slightlysmaller than (e.g., between approximately 1% and 10% less than) afinished or desired part (e.g., the part 100).

A formable insert (e.g., the formable insert 102 of FIGS. 1A and 1B) isthen applied to the frame (block 904). For example, the formable insert102 may be applied to the first frame 114 as shown in FIG. 4. Theformable insert may include an adhesive (e.g., the adhesive 314) and/ora backing to facilitate adhesion and/or shaping of the formable insertto the frame. The formable insert may be pressed on the frame and heatmay be applied to facilitate shaping and/or adhesion of the formableinsert to the frame.

The frame, having the attached formable insert, is then positioned in acavity of a mold tool (block 906). Once the frame and the attachedformable insert are positioned in the mold tool, a portion (e.g., thelip 502 of FIG. 5 and FIG. 7) of the foldable insert is folded relativeto a parting line (e.g., the parting line 704) of the mold tool and/orrelative to perimeter edges of the frame (block 908). For example, asshown in FIG. 7, the slide 700 may be employed to fold the lip 502toward the inner surface 112 of the first frame 114.

With the portion folded of the foldable insert relative to the perimeteredges of the frame, a second material is injected in the mold toolbetween an edge of the frame and an edge of the foldable portion of theformable insert to encase, capture, embed and/or otherwise couple theformable insert relative to the frame (block 910). For example, theinjected material may form another frame (e.g., the second frame 116 ofFIG. 8) to capture or couple the edge of the formable insert relative tothe frame. The frame and the other frame may be composed of the samematerial and/or different materials and may be formed as substantiallyunitary structures.

The present disclosure may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrativeand not restrictive. The scope of the disclosure is, therefore,indicated by the appended claims rather than by the foregoingdescription. All changes that come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

What is claimed is:
 1. A method of forming a cover with a formableinsert, the method comprising: attaching a formable insert to a firstframe portion of the cover, wherein the first frame portion is formedbefore attaching the formable insert to the first frame portion;applying heat to the formable insert to form the formable insert to ashape of the first frame portion; and forming a second frame portion ofthe cover via injection molding subsequent to the formation of the firstframe portion to capture a perimeter edge of the formable insert in thesecond frame portion of the cover, wherein the second frame portion ofthe cover is smaller than the first frame portion of the cover.
 2. Themethod of claim 1, wherein forming the second frame portion to capturethe perimeter edge of the formable insert comprises encasing theperimeter edge in the second frame portion such that the perimeter edgeof the formable insert is not visible from an exterior surface of thecover.
 3. The method of claim 1, further comprising providing a foldableportion or lip of the formable insert that protrudes from respectiveperimeter edges of the first frame portion when the formable insert isattached to the first frame portion.
 4. The method of claim 1, furthercomprising forming the first frame portion via injection molding.
 5. Themethod of claim 1, further comprising positioning the first frameportion and the attached formable insert in a cavity of a mold toolprior to the injection molding.
 6. The method of claim 5, furthercomprising folding the foldable portion of the formable insert toward aninner surface of the first frame portion via a slide prior to theinjection molding.
 7. The method of claim 1, wherein forming the firstframe portion comprises forming the first frame portion to have a firstsurface area of approximately between 90% and 99% of a surface area ofthe cover.
 8. The method of claim 1, wherein forming the second frameportion comprises forming the second frame portion to have a surfacearea of approximately between 1% and 10% of a surface area of the cover.9. The method of claim 1, wherein forming the first frame portioncomprises forming the first frame portion to have a first dimensionalvalue that is less than a respective dimensional value of the cover. 10.The method of claim 9, wherein forming the second frame portioncomprises forming the second frame portion to have a second dimensionalvalue that is substantially equal to the difference between therespective dimensional value of the cover and the first dimensionalvalue of the first frame portion.
 11. The method of claim 10, whereinthe respective dimensional value of the cover comprises a dimensionalheight of a side of the cover.
 12. The method of claim 1, wherein theformable insert comprises leather.
 13. A method of forming a cover witha formable insert, the method comprising: forming a first frame composedof a first material, the first frame having a first dimensional heightthat is less than a respective dimensional height of the cover, whereinthe first frame defines an opening to receive a feature of a mobiledevice; applying heat to the formable insert to form the formable insertto a shape of the first frame; applying the formable insert to the firstframe such that a foldable portion of the formable insert protrudes fromrespective perimeter edges of the first frame; positioning the formableinsert and the first frame in a mold tool; folding the foldable portionof the formable insert relative to respective perimeter edges of thefirst frame such that the perimeter edges of the formable insert areoriented toward an inner surface of the first frame; and injecting asecond material adjacent the folded portion of the formable insert tocapture the perimeter edges of the formable insert in the secondmaterial, wherein a volume of the injected second material is smallerthan a volume of the first material that forms the first frame.
 14. Themethod of claim 13, wherein injecting the second material comprisesinjecting the second material in the mold tool between the foldableportion and the first frame to define a second frame of the cover. 15.The method of claim 14, further comprising placing the first frame andthe formable insert in the mold tool prior to forming the second frame.16. The method of claim 13, further comprising folding the formableinsert toward the inner surface of the first frame when the formableinsert and the first frame are positioned in the mold tool.
 17. Themethod of claim 13, further comprising folding the foldable portiontoward the inner surface of the first frame via a slide of the moldtool.
 18. The method of claim 13, further comprising forming the secondframe to have a second dimensional height that is substantially equal toa difference between the dimensional height of the cover and the firstdimensional height of the first frame.